KR101267741B1 - Zoned topsheet - Google Patents

Abstract

An absorbent article is disclosed that has a topsheet and an absorbent core that is face to face with the topsheet. The topsheet has a center region, an inner middle region, an outer middle region, and an edge region, wherein the inner middle region is between the center region and the outer middle region, and the outer middle region is between the inner middle region and the edge region. The central region texture, the inner middle region texture, the outer middle region texture, and the edge region texture are different from each other. At least one of the central region, the inner middle region, the outer middle region, and the edge region includes tufted fibers. The central region is on the longitudinal center line of the absorbent article.

Description

Zoning Top Sheets {ZONED TOPSHEET}

The present invention relates to a topsheet for an absorbent article.

Absorbent articles such as sanitary napkins, diapers, adult incontinence products, and the like are designed to be worn in close proximity to the wearer's crotch. Absorbent articles should provide fluid collection and retention and should be comfortable for the wearer.

In use, absorbent articles are stressed by various fluid handling requirements. For example, a fluid flow may be applied to the central portion of the pad that may be a trickle or gush of the fluid. When the wearer is lying directly or lying down, the fluid may tend to flow out from the front or rear ends of the absorbent article. Typical absorbent articles are generally the same width as the wearer's crotch, which may be slightly narrower. Thus, there is a possibility that fluid may flow out of the side of the absorbent article, contaminating the wings of the absorbent article, if present, or contaminating the wearer's underwear and / or clothing.

The crotch region of a woman can include many different types of tissue. For example, the pubic area, the labia majora, the inner thigh, and the anus may each have different skin tissues. Sanitary napkins generally cover the labia, the crotch portion in front of the labia, the crotch portion behind the labia, and the crotch portion laterally adjacent to the labia. When a woman wearing a sanitary napkin moves, part of the sanitary napkin may rub against the surrounding body surface. Considering the complex geometry of the female crotch region and the dynamic geometric shape of the female crotch when the female is moving, different parts of the female crotch are exposed to different frictional forces, and the friction between the sanitary napkin and the wearer's crotch depends on the position. Can change.

The moisture and chemical environment of a woman's crotch can also change as a function of location. For example, labia majora may be exposed to menstrual secretions and / or urine. The middle part of a woman's pussy may be exposed to sweat. The part adjacent to the middle area may be exposed to more moisture due to the lack of hair and the tendency of the female panties to fit tightly to the medial thighs and the joints of the crotch and genitals. Areas near the anus may be exposed to more sweat and anal leakage than areas farther from the anus.

Given the various fluid handling needs imparted on different portions of the absorbent article, different physical interactions between portions of the absorbent article and portions of the wearer's body, and different moisture and chemical environments of different portions of the wearer's crotch region, Topsheets having different textures arranged to provide fluid comfort gain where needed, skin comfort gain where needed, topsheet where both fluid handling benefit and skin comfort benefit are required There is a constant and unresolved need for absorbent articles, where a texture is provided that can accept both needs in the area of.

An absorbent article is disclosed that includes a topsheet and an absorbent core in facing relationship with the topsheet. The topsheet has a longitudinal centerline and a transverse centerline. The topsheet includes a central region, an inner middle region, an outer middle region, and an edge region. The inner middle region is between the middle region and the outer middle region, and the outer middle region is between the inner middle region and the edge region. The central region has a central region body facing surface with a central region texture. The medial medial region has an medial medial body opposing surface with medial medial texture. The outer middle region has an outer middle region body facing surface with an outer middle region texture. The edge region has an edge region body facing surface with an edge region texture. The central region texture is different from the inner middle texture, the outer middle region texture, and the edge region texture. The inner middle region texture is different from the outer middle region texture and the edge region texture. The outer middle region texture is different from the edge region texture. The central region is on the longitudinal center line. At least one of the central region, the inner middle region, the outer middle region, and the edge region includes tufted fibers.

1 is a schematic view of the plane of the sanitary napkin.
2 is a schematic view of the plane of the sanitary napkin.
3 is a schematic view of a film with raised portions.
4 is a schematic view of an apertured film.
5 is a schematic representation of a nonwoven with tufts.
6 is a schematic view of a nonwoven with an embossed portion.
7 is a schematic view of the plane of the sanitary napkin.
8 is a schematic representation of a cross section of the sanitary napkin, taken perpendicular to the longitudinal center line.
9 is a schematic representation of a cross section of the sanitary napkin, taken perpendicular to the longitudinal center line.
10 is a schematic representation of a cross section of the sanitary napkin, taken perpendicular to the longitudinal center line.
11 is a schematic representation of a cross section of the sanitary napkin, taken perpendicular to the transverse centerline.
12 is a schematic view of the plane of the sanitary napkin.
13 is a schematic representation of a cross section of a nonwoven web with tufts.
14 is a schematic representation of an apparatus for forming an opening.
15 is a schematic representation of an apparatus for forming an opening.
16 is a schematic view of a toothing roll.
17 is a view of an apertured web.
18 is a schematic view of a film with raised portions.
19 is a schematic representation of a forming screen.
20 is a schematic representation of an apparatus for forming an opening.
21 is a schematic representation of an apparatus for forming an opening.
22 is a schematic representation of an incremental stretching device.
23 is a schematic representation of a nonwoven with tufts.
24 is a schematic representation of a nonwoven with tufts.
25 is a schematic representation of an apparatus for forming a tuft.
26 is a schematic representation of a tooth for forming a tuft.

1 is a diagram of one embodiment of an absorbent article 10 that provides different skin health and fluid collection benefits for different portions of a wearer's crotch. The absorbent article 10 can include a liquid permeable topsheet 20, a fluid impermeable backsheet 30, and an absorbent core 40 disposed between the topsheet 20 and the backsheet 30. Topsheet 20 may be described as being in a facing relationship with absorbent core 40. The absorbent article can be selected from the group consisting of incontinence products, sanitary napkins, and diapers.

The absorbent core is obtained from Bucky Technologies, Inc., Memphis, Tennessee, which is decomposed and formed into a core having a density of about 0.07 grams per cubic centimeter and a caliper of about 10 mm. It may be composed of cellulosic material, such as Poly Fluff possible. Absorbent core 40 may be a high internal phase emulsion foam or polyacrylate material.

Absorbent articles 10 are discussed herein in connection with what is commonly referred to in the art as a sanitary napkin, menstrual pad, or catamenial pad. It should be understood that the absorbent article 10 may be any absorbent article designed to be worn close to the wearer's crotch.

The absorbent article 10 and each layer or component thereof may be described as having a body facing surface and a garment facing surface. As can be appreciated by considering the end use of absorbent articles such as sanitary napkins, diapers, incontinence products, and the like, the body facing surface is the surface of a layer or component that is oriented closer to the body when in use, and the garment facing surface is used. A surface that is oriented closer to the wearer's clothing when in use. Thus, for example, the topsheet 20 has a body facing surface 22 (which may actually be a body contacting surface) and a garment facing surface opposite the body facing surface 22. The garment facing surface of the backsheet 30 may, for example, be oriented closest to the wearer's panties in use and in contact with the panties.

The topsheet 20 may include a central region 50, an inner middle region 60, an outer middle region 70, and an edge region 80. The inner middle region 60 may be between the central region 50 and the outer middle region 70. The outer middle region 70 may be between the inner middle region 60 and the edge region 80. Thus, starting from the intersection of the longitudinal center line L and the transverse center line T and moving towards the periphery 27 of the absorbent article, the various regions are the central region 50, the medial intermediate region 60, the outer intermediate region. The region 70 and the edge region 80 may be arranged in this order. At least a portion of the central region 50 may be on the longitudinal center line L. FIG. At least a portion of the central region 50 may be on the longitudinal center line L and the transverse center line T. FIG.

Longitudinal centerline (L) and transverse centerline (T)-longitudinal centerline (L) and transverse centerline (T) are orthogonal to each other-in the illustrated embodiment, absorbed using a high speed commercial manufacturing line It defines a two-dimensional plane of the absorbent article 10 before use, associated with a machine direction (MD) and a cross machine direction (CD) as is commonly known in the art of making articles. The absorbent article 10 has a length that is the longest dimension measured parallel to the longitudinal axis L. FIG. The article 10 has a width that is, for example, a dimension measured with CD parallel to the transverse centerline T. The width may vary along the length of the sanitary napkin or may be substantially constant. In general, the width can be measured between the lateral side edges 23 parallel to the transverse centerline T. Lateral lateral edges 23 are generally longitudinally aligned and may be straight, curved, or a combination of straight and curved sections.

As shown in FIG. 1, the central region 50, the inner middle region 60, the outer middle region 70, and the edge region 80 may be disposed on a line generally parallel to the transverse center line T. FIG. Can be. The central region 50, the medial middle region 60, the outer middle region 70, and the edge region 80 may be disposed on a line deviating by less than about 30 degrees from alignment with the transverse centerline T. FIG. .

As used herein, the word "region" refers to an area that is partitioned as distinct from surrounding or adjacent areas. Thus, a topsheet comprising evenly spaced openings, each of the same size, over the entire surface of the topsheet, for example, cannot be considered to have any area. Also, for example in a topsheet comprising uniformly spaced openings, each of the same size, a single opening and a material surrounding locally cannot be considered as a region, which is a material that surrounds such a single opening locally. Is not distinguished from surrounding or adjacent areas. Similarly, a topsheet that includes equally spaced elements where each element is the same, for example over the entire surface of the topsheet, cannot be considered to have any area. In addition, in a topsheet comprising evenly spaced elements, for example, a single element and a material surrounding locally may not be considered an area. The regions may be separated from each other such that there is no material of similar structure between the regions. One region may comprise an area that exceeds approximately the product of approximately 5% of the length of the absorbent article and 5% of the width of the absorbent article, the width of each region (ie, the central region 50, the inner middle region 60). ), The middle region 70, and the specific region selected from the edge region 80).

Individually, any of the central region 50, the medial intermediate region 60, the outer intermediate region 70, and the edge region 80 is between the lateral side edges 23 at the location of the center of the region. It may comprise more than about 5% of the width of the absorbent article 10 when measured. Individually, any of the central region 50, the medial intermediate region 60, the outer intermediate region 70, and the edge region 80 is between the lateral side edges 23 at the location of the center of the region. When measured, more than about 10% of the width of the absorbent article 10 may be comprised. Individually, any of the central region 50, the medial intermediate region 60, the outer intermediate region 70, and the edge region 80 is between the lateral side edges 23 at the location of the center of the region. It may comprise more than about 20% of the width of the absorbent article 10 as measured. Thus, in one exemplary embodiment, the central region 50 may constitute about 30% of the width of the absorbent article, and the inner middle region 60 may constitute about 10% of the width of the absorbent article, The outer middle region 70 may constitute about 15% of the width of the absorbent article, and the edge region 80 may constitute about 10% of the width of the absorbent article.

The central region 50 has a central region body facing surface 52. The central region body facing surface 52 has a central region texture 54. Inner medial region 60 has an medial medial body opposing surface 62. The inner middle body opposing surface 62 has an inner middle region texture 64. The outer middle region 70 has an outer middle region body facing surface 72. The outer middle region body facing surface 72 has an outer middle region texture 74. Edge region 80 has an edge region body facing surface 82. Edge region body facing surface 82 has edge region texture 84.

The central region texture 54, the inner middle region texture 64, the outer middle region texture 74, and the edge region texture 84 can be designed to provide certain benefits regarding fluid handling and / or comfort.

As used herein, texture refers to the topography of the relevant material in a direction orthogonal to the plane defined by the longitudinal centerline (L) and the transverse centerline (T). Topography of a material is, for example, by a portion of the material that is higher or lower than the adjacent portion of the material, a hole through the material, and a portion of the material that is plastically interrupted or disturbed with respect to the adjacent portion of the material. Can be provided. Topography can be characterized at a resolution of about 100 micrometers over an area of at least about 4 square millimeters.

For some absorbent articles 10, the channels, indentations, dimples, and / or embossments may have a central region 50, an inner middle region 60, an outer middle region 70. Embodiments are contemplated that may not be considered to provide the texture of any of the edge regions 80, and. For such a design, the texture for the region may be provided by structures other than channels, indentations, dimples, and / or embossed portions. As used herein, a "channel" is an indentation having an in-plane length greater than the width, the length being the longest dimension that is curved or straight within the indentation, and the in-plane width is the shortest dimension of the indentation. to be. An indentation, dimple, or embossing may be considered a structure created by compressing a portion of the absorbent article.

The central region texture 54 can be different from the inner middle region texture 64, the outer middle region texture 74, and the edge region texture 84. Inner middle region texture 64 may be different from outer middle region texture 74 and edge region texture 84. The outer middle region texture 74 may be different from the edge region texture 84. When arranged in this manner, the central area texture 54, the inner middle area texture 64, the outer middle area texture 74, and the edge area texture 84 are at different locations on the body facing surface of the topsheet 20. They may differ from each other to provide different fluid handling and / or comfort gains.

In the embodiment shown in FIG. 1, the central region texture 54 can be designed to provide an area of the topsheet 20 that can quickly capture and retain fluid. The inner mid-area texture 64 is softened so that the topsheet 20 does not irritate the wearer's labia when the absorbent article 10 is worn, and / or towards the side edge 23 of the absorbent article 10 or It may be designed to provide resistance to lateral flow on the body facing surface of the topsheet 20 to reduce the likelihood of fluid leaking out of the absorbent article 10 due to leakage therefrom. The outer mid-area texture 74 may be designed to be comfortable to the skin between the wearer's labia and medial thighs and to provide resistance to lateral fluid flow on the body facing surface of the topsheet 20. Edge area texture 84 provides a smooth surface that may come into contact with the wearer's inner thigh when the absorbent article 10 has a flap 25 that is adapted to be folded around the edge of the wearer's panties. And, to provide resistance to lateral fluid flow on the surface of the topsheet 20 that can cause contamination of the wearer's skin, in, or clothing.

The central region 50, the inner middle region 60, the outer middle region 70, and the edge region 80 may be disposed on a line generally parallel to the longitudinal center line L, as shown in FIG. 2. Can be. The central region 50, the medial intermediate region 60, the outer intermediate region 70, and the edge region 80 may be disposed on a line that is about 30 degrees or less away from alignment with the longitudinal center line L. FIG. . Individually, any of the central region 50, the inner middle region 60, the outer middle region 70, and the edge region 80 is the length of the absorbent article 10 when measured along the longitudinal axis L. FIG. Greater than about 1/20, or greater than about 1/10. Individually, any of the central region 50, the inner middle region 60, the outer middle region 70, and the edge region 80 is the length of the absorbent article 10 when measured along the longitudinal axis L. FIG. More than about 5% of the total weight. Individually, any of the central region 50, the inner middle region 60, the outer middle region 70, and the edge region 80 is the length of the absorbent article 10 when measured along the longitudinal axis L. FIG. More than about 10% of the total weight. Thus, in one exemplary embodiment, the central region 50 can constitute about 30% of the length of the absorbent article 10, and the inner middle region 60 is about 10% of the length of the absorbent article 10. And the outer middle region 70 may constitute about 15% of the length of the absorbent article 10, and the edge region 80 may constitute about 10% of the length of the absorbent article 10. Can be.

Individually, the central region 50, the inner middle region 60, the outer middle region 70, and the edge region 80 each of the absorbent article defined by the longitudinal center line L and the transverse center line T. The area measured in the plane may constitute more than about 10% of the area of the topsheet 20. Individually, each of the central region 50, the medial middle region 60, the outer medial region 70, and the edge region 80 may constitute more than about 5% of the area of the topsheet. Individually, each of the central region 50, the medial intermediate region 60, the outer intermediate region 70, and the edge region 80 may constitute more than about 2% of the area of the topsheet.

In the embodiment shown in FIG. 2, the central region texture 54 can be designed to provide an area of the topsheet 20 that can quickly capture and retain fluid. The inner middle region texture 64 is softened so that the topsheet 20 does not irritate the wearer's labia when the absorbent article 10 is worn, and / or generally on the longitudinal centerline L of the absorbent article 10. The fluid flows without being collected by the absorbent article 10 by leakage toward or from the first end edge 28 or the second end edge 29 of the absorbent article 10, which are end edges located at the edge. It may be designed to provide resistance to lateral flow on the surface of the topsheet 20 to reduce the likelihood of exit. Leakage of fluid from the topsheet by a path towards the end edge of the absorbent article 10 may be a problem when the wearer of the absorbent article 10 is lying down or lying down, as may occur when she is sleeping. Can be. The outer mid-area texture 74 is comfortable to the skin between the wearer's labia and anus or between the wearer's labia and the labyrinth, and / or to provide resistance to lateral fluid flow on the surface of the topsheet 20. Can be designed. The edge area texture 84 provides a smooth surface that may come into contact with the wearer's pussy or anus, and / or the body facing surface of the topsheet 20 that may cause contamination of the wearer's skin, within, or clothing. It can be designed to provide resistance to lateral fluid flow on the bed.

The inner middle region 60 is a film 100 having a raised portion 90 (FIG. 3), a film 100 having an opening 110 (FIG. 4), a tufted fiber 206 (tuft 209). Tufted fibers (FIG. 5), nonwoven 130, nonwoven 130 with opening 110, and nonwoven 130 with embossed portion 140 (FIG. 6). And a material selected from the group consisting of a combination thereof. The outer middle region 70 is a tufted fiber 206, a nonwoven fabric 130 having an opening 110, a nonwoven fabric 130, a nonwoven fabric 130 having an embossed portion 140, and a combination thereof. It may comprise a material selected from the group consisting of. Edge region 80 consists of tufted fibers 206, nonwoven fabric 130 with opening 110, nonwoven fabric 130, nonwoven fabric 130 with embossing portion 140, and combinations thereof. It may comprise a material selected from the group.

The central region 50 and the inner middle region 60 may include a film 100 that faces the nonwoven 130. One example of such an arrangement is shown in FIG. 7. Materials in a face-to-face relationship may be related such that they are faced substantially continuously, face-to-face continuously, partially face-to-face, or in face-to-face relationship in which one layer of material is wrapped around or partially wrapped around another material. have. Continuous facing means that at least one entire surface of one material is in effective contact with another material, and effective contact is used because it is rough at some measurement scale, even the flattest of the surfaces. Substantially continuous facing means that most of at least one surface of one material is in effective contact with another material. Partial facing means that more than about 10% of at least one surface of one material is in effective contact with another material. Overlap to the cylindrical absorbent core 40 may be considered to be in face-to-face relationship with the absorbent core 40. The film 100 may be in a substantially continuous, continuous, or partial facing relationship with the nonwoven 130. The film 100 in the central region 50 may include an opening 110 to provide a path for fluid transport through the film 100. Within inner middle region 60, tufted fibers 206 (forming tuft 209) from nonwoven 130 may protrude through film 100. Film 100 and nonwoven 130 are within central region 50, with film 100 being central region body facing surface 52 and nonwoven 130 being between film 100 and absorbent core 40. Can be arranged to be.

In a similar embodiment, the central region 50 may include a film 100 having an opening 110, and the inner middle region 60 may include a film 100 that faces the nonwoven 130. have. In such an arrangement, the film 100 in the central region 50 and the film 100 in the inner middle region 60 may be composed of a single web of material, as shown in FIG. 8. The tufted fibers 206 in the inner middle region 60 may provide resistance to lateral fluid flow on the body facing surface 22 of the topsheet 20 and / or in the opening between the labia. It may provide a smooth texture to portions of the topsheet 20 that may come into contact with the adjacent wearer's body. In addition, as shown in FIG. 8, the body facing surface 22 of the topsheet 20 may be symmetrical about the longitudinal center line L, wherein the medial intermediate regions 60 opposite each other, The outer middle regions 70, and the edge regions 80, are on sides opposite to each other of the longitudinal center line L.

As shown in FIG. 9, the central region 50 and the inner middle region 60 may include a first nonwoven 131 and a second nonwoven 132 in a face-to-face relationship. An example of such an arrangement in which the central region 50, the inner middle region 60, the outer middle region 70, and the edge region 80 are disposed on a line generally parallel to the transverse center line T is shown in FIG. 9. Is shown. The central region 50, the inner middle region 60, the outer middle region 70, and the edge region 80 may be disposed on a line generally parallel with the longitudinal center line L in another embodiment. As shown in FIG. 9, the first nonwoven 131 may form a central region body facing surface 52. The first nonwoven 131 can be designed such that the material can quickly collect fluid and resist the rewetting of the body facing surface of the topsheet 20. The first nonwoven 131 can include an opening 110 to provide for rapid collection of fluid. Within inner middle region 60, tufted fibers 206 from second nonwoven 132 may protrude through first nonwoven 131 to form tuft 209. In some embodiments, such an arrangement of tufted fibers 206 can act as a mechanical joint between the first nonwoven 131 and the second nonwoven 132. The first nonwoven 131 and the second nonwoven 132 are within the central region 50, such that the first nonwoven 131 is the central region body facing surface 52 and the second nonwoven 132 is the first nonwoven 132. And may be disposed between the nonwoven 131 and the absorbent core 40.

Inner middle region 60 may include film 100 with raised portion 90. One example of a design provided by the film 100 having the raised portion 90 where the inner middle region texture 64 may be practical is illustrated in FIG. 10, with the central region texture 54 having an opening 110. It is a film 100 having. The film 100 in the central region 50 and the inner middle region 60 may consist of a single integral web of material. Without being bound by theory, it is believed that the raised portion 90 can provide a separation between the topsheet 20 and the wearer's body, which can provide comfort during wear and improved skin health. 90 can be structured to provide a film with a soft / fluffy feel.

As shown in FIG. 11, the central region 50 may include a film 100 including an opening 110, and the inner middle region 60 may include tufted fibers 206. As shown in FIG. 11, the central region 50, the inner middle region 60, the outer middle region 70, and the edge region 80 are to be disposed on a line generally parallel to the longitudinal center line L. FIG. Can be. Without being bound by theory, the tufted fibers 206 are believed to provide the softness of the topsheet 20 within an area away from the central region 50 and are generally aligned with the longitudinal centerline L. It may provide a barrier or resistance to the outflow of fluid on the body facing surface of the topsheet 20 in the direction. Alternatively, as shown in FIG. 11, the topsheet 20 may be symmetrical about a line parallel to the transverse centerline T, wherein the inner middle regions 60 and the outer middle region opposite one another. The fields 70, and the edge regions 80 are on sides opposite to each other of the transverse center line T or an axis parallel thereto.

The outer middle region 70 and the edge region 80 may include tufted fibers 206, which may form tufts 209, as shown in FIG. 12. The outer intermediate region 70 may have an outer intermediate region tuft area density, and the edge region 80 may have an edge region tuft area density. The single tuft consists of a plurality of tufted fibers 206. Tuft area density is the number of tufts per unit area, the area being measured in a plane coinciding with and / or parallel to the longitudinal center line L and the transverse center line T. The outer middle region tuft area density may be different from the edge region tuft area density. For example, the outer middle region tuft area density may be greater or less than the edge region tuft area density. Without being bound by theory, by changing the tuft area density of different regions of the topsheet 20, the softness of the outer mid-region texture 74 may be made different from the softness of the edge region texture 84. It is considered to be. It is also believed that the higher the tuft area density, the better the tuft provides for resistance to lateral flow on the topsheet.

As shown in FIG. 13, the outer middle region 70 and the edge region 80 may be tufted fibers 206, and the outer middle region 70 may have an outer middle region tuft height H. The edge region 80 may have an edge region tuft height H. Tuft height H is measured as the size in which tufted fibers 206 extend from the surface of the base material on the face on which the tufts protrude. The outer middle region tuft height H may be different from the edge region tuft height H. The outer middle region tuft height H may be greater or less than the edge region tuft height. Without being bound by theory, the tuft height is absorbed from the body where needed, to provide a barrier with sufficient resistance to lateral flow on the topsheet, to provide the desired degree of softness of the area. It is believed to be a design factor that can be controlled to provide separation of the article.

Various textures may be provided for the material for use within the topsheet 20. Materials that are believed to be practical include, but are not limited to, apertured film 100, apertured film 100 having raised portions 90, and apertured nonwovens.

The openings in the web 1 may be formed as shown in FIG. 14 to form the openings 110 in the topsheet 20. Web 1 may be a film or nonwoven. As shown in FIG. 14, the web 1 may be formed from a generally planar two dimensional precursor web 24 having a first face 12 and a second face 14. . Precursor web 24 is, for example, a multilayer film of a polymer film, nonwoven web, woven fabric, paper web, tissue paper web, or knitted fabric, or any of the foregoing. Can be. In general, the term "face" is used herein to describe two major surfaces of generally two-dimensional webs, such as paper and film, in the conventional usage of that term. In a composite or laminate structure, the first face 12 of the web 1 is the first face of one of the outermost layers or plies facing each other, and the second face 14 is the other outermost layer or It is the second side of the ply.

Precursor web 24 may be a polymer film web. The polymeric film web may be deformable. Deformable, as used herein, describes a material that substantially retains its newly formed conformation when stretched beyond its elastic limit.

Polymeric film webs may include usually extruded or cast materials, such as films such as polyolefins, nylons, polyesters, and the like. Such films can be thermoplastic materials such as polyethylene, low density polyethylene, linear low density polyethylene, polypropylene, and copolymers and blends containing significant fractions of these materials.

Precursor web 24 may be a nonwoven web. In the case of the nonwoven precursor web 24, the precursor web 24 can include unbonded fibers, entangled fibers, tow fibers, and the like. The fibers may be stretchable and / or elastic and may be pre-extended for processing. The fibers of the precursor web 24 may be continuous as produced by the spunbonded method, or may be cut to length, typically as used in a carded process. The fibers may be absorbent and may comprise a fibrous absorbent gelling material. The fibers can be bicomponent, multicomponent, shaped, crimped, or can be nonwoven webs and any other formulations or configurations known in the textile art.

Nonwoven precursor web 24 may be any known nonwoven web that includes nonwoven web 25 that includes polymeric fibers having sufficient stretching properties to form a nonwoven 130 having openings 110. In general, the polymer fibers may be bondable by any one of chemical bonding (eg, by latex or adhesive bonding), pressure bonding, or thermal bonding. Nonwoven precursor web 24 may comprise about 100% by weight thermoplastic fibers. Nonwoven precursor web 24 may include as little as about 10% by weight thermoplastic fibers. Likewise, nonwoven precursor web 24 may include any amount of thermoplastic fibers in an increment of from about 10% to about 100% to 1% by weight.

The total basis weight of the precursor web 24 (including the laminate or multilayer precursor web 24) may range from about 8 gsm to about 500 gsm, depending on the end use of the web 1. In 1 gsm increments. The constituent fibers of the nonwoven precursor web 24 may be polymeric fibers and may comprise monocomponent, bicomponent and / or bicomponent fibers, hollow fibers, non-round fibers (eg, shaped (eg, , Trilobal fibers or capillary channel fibers), with major cross-sectional dimensions (e.g., diameter for circular fibers, long axes for elliptical fibers, in the range of about 0.1 to about 500 microns in 0.1 micron increments). , In the case of irregular shapes, the longest linear dimension).

The feed roll 152 is a nip of rolls 102, 104 where the precursor web 24 rotates in a pair of opposite directions on or around any of a variety of idler rollers, tension-control rollers, and the like. When moved in the machine direction by means known in the art, including the direction to 116, it rotates in the direction indicated by the arrow in FIG. Rolls 102 and 104 may include forming apparatus 103. The pair of rolls 102, 104 may operate to form volcanic shaped structures 8 and openings in the precursor web 24. The apertured web 1 may be wound on the winding roll 180.

There are various approaches for creating openings in a web. Factors that may affect the approach chosen to create the opening 110 include whether the precursor web 24 is a nonwoven or a polymer film, the desired geometry of the opening, the desired processing speed, and the desired process control range. Including but not limited to.

One approach to forming openings in polymeric film webs and nonwoven webs is a pair of intermeshing, as shown in FIG. 15 and disclosed in US Patent Application No. 11 / 249,618 by O'Donnell et al. rolls 102 and 104 are employed. Referring to FIG. 15, the portion of the apparatus shown in FIG. 14 that can form the apertured web 1 is shown in more detail. The shaping device 103 may comprise a pair of steel engagement rolls 102, 104, each rotating about an axis A, the axes A being parallel and in the same plane. Forming apparatus 103 may be designed such that precursor web 24 is maintained on roll 104 through a predetermined angle of rotation. FIG. 15 shows in principle what happens when precursor web 24 proceeds straight through nip 116 on forming apparatus 103 and exits as apertured web 1. Precursor web 24 or apertured web 1 is roll 102 or roll through a predetermined angle of rotation before or after nip 116 (for precursor web 24) or after (for web 1). It may be partially wound on any one of the 104.

The roll 102 may include a plurality of ridges 106 and corresponding valleys 108 that may extend uninterrupted around the entire circumference of the roll 102. Depending on the type of pattern required in the apertured web 1, the roll 102 may include a ridge 106 partially removed by, for example, an etching, milling or other machining process, such that the ridges 106 Some or all of) are not continuous in the circumferential direction and have interruptions or gaps. The ridges 106 may be spaced apart from each other along the axis A of the roll 102. For example, the middle third of roll 102 may be smooth, and the outer thirds of roll 102 may have a plurality of ridges spaced from each other. Similarly, the ridges 106 on the middle third of the roll 102 may be spaced closer to each other than the ridges 106 on the outer thirds of the roll 102. The stops or gaps may be arranged to form a pattern, including a geometric pattern such as a circle or diamond, in the circumferential direction, the axial direction, or both directions. In one embodiment, roll 102 may have teeth similar to teeth 510 on roll 104 described below. In this way it is possible to have a three-dimensional opening with parts extending outwards on both sides of the apertured web 1.

The roll 104 may include a plurality of rows of circumferentially extending ridges that are deformed into several rows of circumferentially spaced teeth 510 that extend in a spaced apart relationship at least about a portion of the roll 104. Individual rows of teeth 510 of roll 104 may be separated by corresponding grooves 112. In operation, the rolls 102, 104 extend the ridge 106 of the roll 102 into the grooves 112 of the roll 104 and the teeth 510 of the roll 104 extend the valleys 108 of the roll 102. ) To extend into). Either or both of the rolls 102, 104 may be heated by means known in the art, such as incorporating hot oil filled rollers or electro-heated rollers. Alternatively, either or both of the rolls may be heated by surface convection or by surface radiation.

A schematic cross-sectional view of a portion of the engagement rolls 102, 104 including ridge 106 and representative teeth 510 is shown in FIG. 16. As shown, teeth 510 are referred to as tooth height TH (note that TH may also be applied to ridge 106 height and that tooth height and ridge height may be the same) and pitch P Tooth-to-tooth spacing (or ridge-to-ridge spacing). As shown, the depth of engagement (DOE) E is a measure of the level of engagement of the rolls 102, 104 and is measured from the tip of the ridge 106 to the tip of the tooth 510. Engagement depth E, tooth height TH, and pitch P can be varied as desired depending on the properties of precursor web 24 and the desired properties of apertured web 1. The rolls 102 and 104 may be made of wear resistant stainless steel.

The opening area density (number of openings 110 per unit area) can vary from about 1 opening / cm 2 to about 6 openings / cm 2, up to about 60 openings / cm 2 in increments of 1 opening / cm 2. For example, at least about 10 apertures / cm2, or at least about 25 apertures / cm2.

As can be appreciated in connection with the forming apparatus 103, the opening can be made by mechanically deforming the precursor web 24, which can be described as being generally planar and two-dimensional. "Planar" and "two dimensional" is simply a clear out-of-plane z-direction 3 imparted due to the formation of a generally conical shaped structure 8 in which the precursor web 24 is truncated. It means that it can be flat compared to the finished apertured web 1 with dimensionality. "Plane" and "two-dimensional" are not intended to mean any particular flatness, smoothness or dimensionality, and soft fibrous nonwoven webs may be planar in their as-made conditions.

As the precursor web 24 proceeds through the nip 116, the teeth 510 of the roll 104 enter the valley 108 of the roll 102 to form an opening 110 and simultaneously withdraw material from the precursor web. Pressed out of the plane of (24), the opening is defined by the rim of the truncated generally conical shaped structure (8). Indeed, teeth 510 exit through the precursor web 24. When the tip of the tooth 510 exits the precursor web 24, the web material may be pressed out of the plane of the precursor web 24 by the tooth 510 and may elongate and / or plastically deform in the z-direction. This produces an out-of-plane geometry characterized by the conical shaped structure 8 and the opening 110. The truncated generally conical shaped structure 8 may be considered a volcanic shaped structure.

FIG. 17 shows one embodiment of a three-dimensional apertured web 1, where precursor web 24 is not a flat film but microscopic raised portions 90 that can be formed for use within topsheet 20. Film was pre-textured. The raised portion 90 may be bumps, holes, or the like. In the illustrated embodiment, the raised portion 90 is also a volcanic shaped micro aperture formed by a hydroforming process. Suitable hydroforming processes are the first stage of the multistage hydroforming process disclosed in US Pat. No. 4,609,518, issued to Curro et al. On September 2, 1986. The hydroforming screen used for the web shown in FIG. 17 was a “100 mesh” screen, and the film was obtained from Tredegar Film Products, Ter Haut, Indiana, USA. The opening 110 defined by the rim of the truncated generally conical shaped structure 8 may be formed by teeth 510 of the roll 104 of the forming apparatus 103. The truncated generally conical shaped structure 8 may be oriented in the topsheet 20 such that the rim of the truncated generally conical shaped structure 8 is on the body facing side of the topsheet. The truncated generally conical shaped structure 8 may be oriented in the topsheet 20 such that the rim of the truncated generally conical shaped structure is on the garment facing side of the topsheet 20. The truncated generally conical shaped structure 8 has a portion of the rim of the truncated generally conical shaped structure on the garment facing side of the topsheet 20 and a portion of the truncated generally conical shaped structure 8 is Orient within the topsheet 20 such that it is on the body facing side of the topsheet 20.

The openings of the film embodiment shown in FIG. 17 were fabricated on an apparatus such as that shown in FIG. 14, where the forming apparatus 103 is one patterned roll, such as roll 104 and one non-patterned roll. Arranged to have 102. In certain embodiments, the nip 116 may be formed by using two patterned rolls having either of the same or different patterns in the same or different corresponding regions of each roll. Such a device can not only produce webs with openings protruding from both sides of the apertured web 1, but also provide large-textures, such as aberrations, micro-openings, or micro-patterns to the web 1. ) Can be produced. Likewise, with a number of forming devices 103, it may be desirable for the apertured web 1 to be re-treated to have additional truncated generally conical shaped structures 8 and / or openings. For example, the larger opening area density of the truncated generally conical shaped structure 8 on the apertured web 1 may be achieved by treating the precursor web 24 through two or more forming devices 103, or by using teeth ( By reducing the spacing between 510.

The number, aperture area density, size, geometry, and out-of-plane geometry associated with the opening may vary the number of teeth 510, the spacing therebetween, the geometry, and the size of the teeth 510 and / or the roll 104 and / or roll ( Can be varied by making corresponding dimensional changes as needed in 102).

The raised portion 90 may be fibrils to provide a texture that provides a soft hand, as shown in FIG. 18. 18 is an enlarged fragmentary perspective view of a fluid permeable, macroscopically enlarged, three-dimensional apertured web 1. The apertured web 1 may have an opening 110 that provides fluid communication between opposing faces of the apertured web 1. The opening 110 may be defined by a continuous network of interconnecting members, such as members 191, 192, 193, 194, 195 interconnected with respect to each other. The shape of the opening 110 may be a polygon, including but not limited to, an ordered or random pattern, square, hexagon, and the like. The opening 110 may be in the shape of a modified ellipse, and in one embodiment, the opening 110 may be generally in the shape of a tear drop. Polymer web 1 represents a plurality of raised portions 90 in the form of hair-like fibrils 225, described in more detail below.

In the three-dimensional microopening formed polymer web 1, each interconnect member may comprise a base portion, such as a base portion 181, each base portion having a sidewall portion, such as a respective longitudinal edge thereof. May have sidewall portions 183 extending therefrom. The side wall portion 183 generally extends in the direction of the opposite surface of the web 1, and may be coupled to the side walls of adjacent interconnecting members.

The raised portion 90 may be formed in the web using, for example, a forming structure 350 as shown in FIG. 19. 19 shows a portion of a forming structure 350 of the present invention in a partial perspective view. The forming structure 350 shows a plurality of forming structure openings 710 defined by interconnecting members 910 of the forming structure. The forming structure opening 710 is formed between the opposing surfaces, ie, the forming structure second surface 850 in the plane of the forming structure first surface 900 and the second surface 1060 in the plane of the first surface 1020. Allow fluid communication between them. The forming structure sidewall portion 830 generally extends between the forming structure first surface 900 and the forming structure second surface 850. The protrusion 2200 can extend from the forming structure first surface 900 and can be generally columnar in shape.

The comparison with FIG. 18 of FIG. 19 shows the overall correspondence of the forming structure 350 with the polymer web 1. That is, the three-dimensional protrusion 2200 and the forming structure opening 710 of the forming structure 350 generally have a one-to-one correspondence with respect to the raised portion 90 and the opening 110 of the polymer web 1, respectively. .

The raised portion 90 may be formed in the polymer web 1 by the forming structure 350 using various processes known in the art, including but not limited to hydroforming, vacuum forming, and direct casting. . The forming structure 350 may be arranged as a cylindrical drum that rotates about an axial axis. US Pat. No. 7,402,723 to Stone et al., Issued July 22, 2008, discloses polymeric webs having raised portions and methods for forming such polymeric webs. Polymer webs, such as those employed in Always Ultra sanitary napkins, sold by Procter & Gamble Co., Cincinnati, Ohio, may be used for the topsheet 20 or its components / parts. It may be practical.

Rising portions 90 other than hollow, generally columnar fibrils are contemplated. Softness may be beneficial when web 1 is employed as part of a topsheet in a disposable absorbent article. A soft and flexible topsheet 20 for the absorbent article 10 can be achieved when the apertured web 1 is used with the second side 14 having the raised portion 90 as the body facing surface of the article. In some embodiments, raised portion 90 may be on the garment facing side of topsheet 20 to provide different levels of comfort or different properties related to the flow of fluid.

A technique for forming a nonwoven 130 having an opening 110 that can be used to form the topsheet 20 is shown in FIG. 20. Referring to FIG. 20, a process and apparatus for selectively opening a nonwoven web suitable for use as the topsheet 20 on an absorbent article 10 is schematically illustrated. US patent application Ser. No. 11 / 249,618, US Pat. No. 5,714,107, and US Pat. No. 5,628,097 disclose openings, devices, and methods of creating openings 110 in a nonwoven web.

The nonwoven precursor web 24 may be disengaged from the feed roll 152 and move in the direction indicated by the arrow associated therewith as the feed roll 152 rotates in the direction indicated by the arrow associated therewith. Nonwoven precursor web 24 passes through nip 116 of web weakening roller device 1108 formed by calender roll 1110 and smooth anvil roller 1112.

Nonwoven precursor web 24 may be formed by known nonwoven extrusion processes, such as, for example, known meltblowing processes or known spunbonding processes, which are first bonded and / or stored on a feed roll. Without passing directly through the nip 116.

Nonwoven precursor web 24 may be stretchable, elastic, or inelastic. Nonwoven precursor web 24 may be a spunbonded web, meltblown web, or bonded carded web. If the nonwoven precursor web 24 is a web of meltblown fibers, it may comprise meltblown microfibers. Nonwoven precursor web 24 may be made of fiber forming polymers such as, for example, polyolefins. Polyolefins include one or more of polypropylene, polyethylene, ethylene copolymers, propylene copolymers, and butene copolymers.

In another embodiment, the nonwoven precursor web 24 is a multilayer material, for example, in which at least one layer of a spunbonded web is bonded to at least one layer of a meltblown web, a bonded carded web, or other suitable material. Can be. For example, nonwoven precursor web 24 has a first layer of spunbonded polypropylene, having a basis weight of about 6.78 to about 270 g / m 2 (about 0.2 to about 8 ounces per square yard), about 6.78 to about 130 g A layer of meltblown polypropylene having a basis weight of about 0.2 to about 4 ounces per square yard, and a weight having a basis weight of about 6.78 to about 270 g / m 2 (about 0.2 to about 8 ounces per square yard). It may be a multilayer web having a second layer of funbonded polypropylene. Alternatively, the nonwoven web may be, for example, a spunbonded web having a basis weight of about 6.78 to about 340 g / m 2 (about 0.2 to about 10 ounces per square yard) or about 6.78 to about 270 g / m 2 (per square yard) Single layer of material, such as a meltblown web having a basis weight of about 0.2 to about 8 ounces).

Nonwoven precursor web 24 may be bonded to the polymer film to form a laminate. Suitable polymeric film materials include polyolefins such as polyethylene, polypropylene, ethylene copolymers, propylene copolymers, and butene copolymers; Nylon (polyamide); Metallocene catalyst-based polymers; Cellulose esters; Poly (methyl methacrylate); polystyrene; Poly (vinyl chloride); Polyester; Polyurethane; Compatible polymers; Compatible copolymers; And blends, laminates, and / or combinations thereof.

Nonwoven precursor web 24 may also be a composite composed of a mixture of two or more different fibers or a mixture of fibers and particles. Such mixtures may be applied to a gas stream in which meltblown fibers or spunbond fibers are conveyed such that a tightly entangled co-mingling of fibers and other materials such as wood pulp, staple fibers and particles occurs prior to collection of the fibers. And / or by adding particles.

The nonwoven precursor webs 24 of the fibers may be joined by bonding to form a coherent web structure. Suitable bonding techniques include, but are not limited to, chemical bonding, thermal bonding, such as point calendering, hydroentangling, and kneeding.

One or both of the patterned calender roll 1110 and smooth anvil roller 1112 may be heated, and the pressure between the two rollers, if present, at the desired temperature and at the plurality of locations, the nonwoven precursor web 24. May be adjusted to provide pressure for simultaneously weakening and melt-stabilizing.

The patterned calender roll 1110 is configured to have a cylindrical surface 1114 and a plurality of protrusions 1216 extending outwardly from the cylindrical surface 1114. The projections 1216 are disposed in a predetermined pattern, with each projection 1216 within the nonwoven precursor web 24 to create a weakened, melt-stabilized position of the predetermined pattern within the nonwoven precursor web 24. It is constructed and arranged to settle the weakened, melt-stabilized position. Incremental stretching system 1132 and incremental stretching rollers 1134, 1136 are also shown in FIG. 20 and discussed in more detail below.

Prior to entering nip 116, the cohesive nonwoven web includes a plurality of fibers joined together by point calendered joints to form a coherent web structure.

Patterned calender roll 1110 may have a repetitive pattern of protrusions 1216 extending around the entire circumference of cylindrical surface 1114. Alternatively, the protrusion 1216 may extend around a portion or portions of the circumference of the cylindrical surface 1114.

By way of example and not limitation, the projection 1216 may be truncated conical shape radially outwardly extending from the cylindrical surface 1114 and having an elliptical distal surface 1117, as shown in FIG. 21. . Other suitable shapes for the distal surface 1117 include, but are not limited to, round, square, rectangular, and the like. The patterned calendar roll 1110 may be finished such that all end surfaces 1117 lie in a virtual staff post that is coaxial with respect to the axis of rotation of the calendar roll 1110.

The protrusion 1216 may be a blade having a long axis circumferentially oriented with respect to the patterned calender roll 1110. The protrusion 1216 may be a blade having a long axis oriented parallel to the axis of rotation of the calender roll 1110.

The protrusions may be placed in any predetermined pattern around the patterned calendar roll 1110. After passing through the weakening roller apparatus 1108, the precursor web 24 may have a plurality of melt stabilized positions 1202. Anvil roller 1112 may be a smooth surface of a steel pillar.

From the weakening roller device 1108, the nonwoven precursor web 24 is formed by a nip formed by an incremental stretching system 1132 employing opposing pressure applicators having a three-dimensional surface that is complementary to each other at least to some degree. Pass 116.

Referring now to FIG. 22, a partial enlarged view of an incremental stretching system 1132 including incremental stretching rollers 1134, 1136 is shown. Incremental stretching roller 1134 extends around the entire circumference of incremental stretching roller 1134 or a plurality of ridges 106 and corresponding valleys that only partially extend around the circumference of incremental stretching roller 1134. 108). Incremental stretching roller 1136 includes a plurality of complementary ridges 106 and a plurality of corresponding valleys 108. Ridge 106 on incremental stretching roller 1134 is engaged or engaged with valley 108 on incremental stretching roller 1136, and ridge 106 on incremental stretching roller 1136 is incremental stretching roller 1134. ) Engages or engages with the valley 108 on the. When the nonwoven precursor web 24 having the weakened, melt-stabilized position 1202 passes through the incremental stretching system 1132, the nonwoven precursor web 24 is tensioned in the CD or width direction, such that the nonwoven precursor Allow the web 24 to extend in the CD direction. Alternatively or additionally, nonwoven precursor web 24 may be tensioned in the MD or machine direction. The tensile force exerted on the nonwoven precursor web 24 coincides with the melt-stabilized position 1202, causing the weakened, melt-stabilized position 1202 to rupture and weaken within the nonwoven precursor web 24. A plurality of molded SAN openings 1204 (SAN stands for Stretch Apertured Nonwoven) may be adjusted to form the apertured web 1. However, the bonds of the nonwoven precursor webs 24 may be strong enough to prevent them from rupturing during tension, thereby keeping the nonwoven webs agglomerated even when the weakened, melt-stabilized position breaks.

Other incremental stretching mechanisms suitable for incrementally stretching or tensioning nonwoven webs are described in WO 95/03765, published February 9, 1995 in the name of Chappell et al.

The apertured nonwoven web 1 may be wound and stored on the winding roll 180. Alternatively, the apertured nonwoven web 1 can be transferred directly to a manufacturing line, where it is used to form a topsheet on a disposable absorbent article.

The texture of tufted fibers 206 may be provided to the substrate for use within the topsheet 20. A plurality of tufted fibers 206 may form tufts 209. Tuft 209 may comprise a laminate web 1 consisting of two or more layers, one of which is pressed into another layer or protrudes through an opening in another layer, an example of which is illustrated in FIG. 23 is shown. These layers are referred to herein as generally planar two-dimensional precursor webs, such as first precursor web 220 and second precursor web 221. Either precursor web can be a film, nonwoven or woven web. The first precursor web 220 and the second precursor web 221 (and any additional webs) may be joined by or without adhesive, thermal bonding, ultrasonic bonding, or the like.

The web 1 has a first side 12 and a second side 14, and the term “side” is a generally planar two-dimensional web, such as paper and film having two sides when in a generally flat state. Used in the usual usage of The first precursor web 220 has a first precursor web first surface 212 and a first precursor web second surface 214. The second precursor web 221 has a second precursor web first surface 213 and a second precursor web second surface 215. The web 1 has a machine direction (MD) and a width direction (CD) as is commonly known in the web fabrication art. The first precursor web 220 can be a nonwoven web, a polymer film, or a woven web composed of substantially randomly oriented fibers. "Substantially randomly oriented" means that due to the processing conditions of the precursor web, the amount of fibers oriented in MD rather than CD may be higher or vice versa. The second precursor web 221 may be a nonwoven web similar to the first precursor web 220 or may be a polymer film or apertured polymer film, such as a polyethylene film.

In one embodiment, the first side 12 of the web 1 is discrete, an exposed portion of the second precursor web first surface 213 and an integral extension of the fibers of the nonwoven first precursor web 220. Defined by one or more tufts 209, which may be tufts 209. Tufts 209 may protrude through openings in the second precursor web 221. As shown in FIG. 23, each tuft 209 may include a plurality of looped fibers 208 oriented out of the plane of the nonwoven. Tuft 209 may pass through second precursor web 221 and extend outward from its second precursor web first surface 213.

The textured region of tuft 209 may comprise a laminate web 1 comprising a first precursor web 220, at least the first precursor web 220 is a nonwoven web 130, and the laminate web ( 1) has a first face 12, the first face 12 comprising a second precursor web 221 and at least one discrete tuft 209, each tuft 209 having a length of about 1 minute. An integral extension of the first precursor web 220 and comprising a plurality of tufted fibers 206 extending through the second precursor web 221, the laminate web 1 having a second side 14, The second face 14 includes a first precursor web 220.

The first precursor web 220 can be a fibrous woven or nonwoven web comprising elastic or elastomeric fibers. The elastic or elastomeric fiber may be stretched by at least about 50% of its original dimension and returned to within 10%. If the fibers are simply displaced by the mobility of the fibers in the nonwoven, or if the fibers are stretched beyond their elastic limits and plastically deformed, tufts 209 can be formed from elastic fibers.

The second precursor web 221 has completeness sufficient for the material to be formed into a laminate by the process described below, and the material has stretching properties relative to the first precursor web 220, such that the second precursor web 221 When the fiber undergoes deformation from the first precursor web 220 which is pressed out of plane in the direction of), the second precursor web 221 is pressed out of the plane (eg by elongation) or ruptured (eg by drawing fracture). Due to tearing), virtually any web material. If a tear occurs, an IPS opening 204 may be formed at the tear location (IPS stands for Inter-Penetrating SELF). A portion of the first precursor web 220 may extend through the IPS opening 204 in the second precursor web 221 to form a tuft 209 on the first face 12 of the web 1. (Ie, "break out" or protrude through it). In one embodiment, the second precursor web 221 is a polymer film. The second precursor web 221 can also be a woven textile web, a nonwoven web, a polymer film, an apertured polymer film, a paper web (eg, tissue paper), a metal foil (eg, an aluminum wrapping foil). ), Foams (eg urethane foam sheeting), and the like.

As shown in FIG. 23, tuft 209 may extend through IPS opening 204 in second precursor web 221. The IPS opening 204 may be formed by locally rupturing the second precursor web 221. The rupture may involve simple cleavage opening of the second precursor web 221 such that the IPS opening 204 is an in-plane (MD-CD) two-dimensional opening. However, for some materials, such as polymer films, a portion of the second precursor web 221 may be deflected or pressed out of the plane (ie, the plane of the second precursor web 221), so that flaps or flaps are used herein. A flap-shaped structure referred to as 207 can be formed. The shape and structure of the flap 207 may depend on the material properties of the second precursor web 221. The flap 207 may have one or more flaps of general structure, as shown in FIG. 20. In another embodiment, flap 207 may have a more volcanic shape, as if tuft 209 is ejecting from flap 207.

The tufts 209 may at some point "break out" (or protrude through) the second precursor web 221 and may be "locked" in place by frictional engagement with the IPS opening 204. This means a certain degree of recovery at the opening that tends to prevent the tuft 209 from being pulled out again through the IPS opening 204. The frictional engagement of the tufts and openings can provide a laminate web structure having a tuft on one side that can be formed without adhesive or thermal bonding.

The tufts 209 are configured to substantially cover the first face 12 of the web 1 when the tufts 209 protrude through the second precursor web 221 (eg, the portion of interest, the zone). , Or close enough to cover about 65%, about 75%, about 85%, or about 95% of the area). In such an embodiment, both sides of the web 1 appear to be nonwoven, where the difference between the first side 12 and the second side 14 is the difference in surface texture. Therefore, in one embodiment, web 1 may be described as a laminate material of two or more precursor webs, where both sides of the laminate web are substantially covered by fibers from only one of the precursor webs.

The looped fibers 208 may be substantially aligned with one another, as shown in FIG. 23. Looped fibers may be arranged such that tufts 209 have a clear linear orientation and long axis LA, as shown in FIG. 23. In the embodiment shown in FIG. 23, the major axis LA is parallel to the MD. Tuft 209 may have a symmetrical shape, such as a circular shape or a square shape, within the MD-CD plane. Tuft 209 may have an aspect ratio greater than 1 (ratio of longest dimension to shortest dimension, both measured within the MD-CD plane). In one embodiment, all spaced tufts 209 have generally parallel long axes LA. The number of tufts 209 per unit area of the web 1, ie, the area density of the tufts 209 may vary from about 1 tuft / cm 2 to about 100 tufts / cm 2. At least about 10, or at least about 20 tufts / cm < 2 >.

Tufts 209 may be formed by pressing the fibers out of plane in the z-direction at discrete, localized portions of the first precursor web 220. Tuft 209 may be formed as shown in FIG. 24, in the absence of second precursor web 221, using a process as described below.

Referring to FIG. 25, an apparatus and method is shown for manufacturing a web 1 that includes a tuft 209 that can be used to form the topsheet 20. The shaping device 103 comprises a pair of engagement rolls 102, 104, each rotating about an axis A, which axes A are parallel in the same plane. Roll 102 includes a plurality of ridges 106 and corresponding valleys 108 that can extend uninterrupted around the entire circumference of roll 102. The roll 104 may include a plurality of rows of circumferentially extending ridges that are deformed into several rows of circumferentially spaced teeth 510 that extend in a spaced apart relationship at least about a portion of the roll 104. Some of the rolls 104 may not have teeth 510 to form a web 1 having portions without tufts 209. The size and / or spacing of the teeth 510 may be varied to enable the formation of the web 1 with different sizes of tufts 209 and / or portions without tufts 209 in different portions. .

Individual rows of teeth 510 of roll 104 are separated by corresponding grooves 112. In operation, the rolls 102, 104 extend the ridge 106 of the roll 102 into the grooves 112 of the roll 104 and the teeth 510 of the roll 104 extend the valleys 108 of the roll 102. ) To extend into). Either or both of the rolls 102, 104 may be heated by means known in the art, such as the use of hot oil filled rollers or electrically heated rollers.

In FIG. 25, the forming apparatus 103 is shown having one patterned roll, such as roll 104, and one non-patterned grooved roll 102. Two patterned rolls 104 having the same or different patterns in the same or different corresponding regions of each roll may be used. The device can be designed to have teeth directed in opposite directions on the opposing rolls. This can form a web in which tufts 209 are created on both sides of the web.

Web 1 mechanically processes precursor webs, such as first precursor web 220 and second precursor web 221, which may each be described as generally planar and two-dimensional before being processed by the apparatus shown in FIG. 25. It can be prepared by deformation. By "planar" and "two-dimensional" it is simply because the formation of the tuft 209 causes the web to start processing in a generally flat state relative to the web 1 having a clear out-of-plane z-direction three-dimensionality. Means that.

The process and apparatus for forming tuft 209 is described in US Pat. No. 5,518,801, entitled "Web Materials Exhibiting Elastic-Like Behavior," followed by a patent document. It is similar in many respects to the process referred to herein as "SELF" web, which means "Structural Elastic-like Film." As described below, the teeth 510 of the roll 104 are associated with leading and trailing edges that allow the teeth to “pierce” essentially the planes of the first precursor web 220 and the second precursor web 221. Has a geometric shape. In a two-layer laminate web, the teeth 510 press fibers out of the plane simultaneously from the first precursor web 220 and through the plane of the second precursor web 221. Thus, tuft 209 of web 1 may be a “tunneled” tuft of looped fiber 208 extending through and away from second precursor web first surface 213 and symmetrically shaped. Can be.

The first precursor web 220 and the second precursor web 221 are provided either directly from their respective web fabrication processes or indirectly from a feed roll, so that the nips 116 of the interlocking rolls 102 and 104 rotate in opposite directions. In the machine direction. The precursor web is preferably maintained in sufficient web tension by means well known in the web handling art to enter the nip 116 in a generally flat state. When the first precursor web 220 and the second precursor web 221 pass through the nip 116, the teeth 510 of the roll 104 that engage with the valleys 108 of the roll 102 are tufted ( A portion of the first precursor web 220 is simultaneously pressed out of the plane of the first precursor web 220 and in some cases through the second precursor web 221 to form 209. Indeed, the teeth 510 "intrude" or "pierce" the fibers of the first precursor web 220 into the plane of the second precursor web 221.

When the tip of the tooth 510 is pressed into or exits the first precursor web 220 and the second precursor web 221, the first precursor web 220 oriented primarily CD across the tooth 510. A portion of the fiber is pressed out of the plane of the first precursor web 220 by the teeth 510. The fibers may be pressed out of plane due to fiber mobility, or they may be pressed out of plane by stretching and / or plastically deforming in the z-direction. The portion of the first precursor web 220 pressurized out of plane by the teeth 510 is pressed into or penetrates into the second precursor web 221 which may rupture due to relatively lower elongation, resulting in a web (1). The tufts 209 are formed on the first surface 12 of.

For a given maximum strain (eg, strain imparted by the teeth 510 of the molding apparatus 103), the second precursor web 221 can actually break under the tensile load created by the imparted strain. That is, in order for the tufts 209 to be disposed on the first face 12 of the web 1, the second precursor web 221 may be tensilely broken so that it is locally broken (ie, at the deformation area). It may be necessary to have sufficiently low fiber mobility (if present) and / or relatively low elongation-to-break so that the trough 209 creates an IPS opening 204 that can extend therethrough.

In one embodiment, the second precursor web 221 has an elongation at break in the range of about 1% to about 5%. The actual required elongation at break depends on the deformation introduced to form the web 1, but in some embodiments, the second precursor web 221 is about 6%, about 7%, about 8%, about 9%, about 10 It is appreciated that it can exhibit a percent elongation at break, or more than that. It is also recognized that the actual elongation at break can depend on the strain which is a function of the line speed for the apparatus shown in FIG. 25. Elongation at break of the web is determined by methods known in the art, such as by standard tensile test methods using standard tensile test equipment such as those manufactured by Instron, MTS, Twin-Albert, and others. Can be measured.

In addition, compared to the first precursor web 220, the second precursor web 221 is, for example, rather than extending out of plane to the extent of the tuft 209, for example, of the forming apparatus 103. Lower fiber mobility (if any) and / or lower elongation at break (i.e., break elongation of individual fibers, or so that they can be tensilely broken under deformation caused by formation of tuft 209 by teeth 510), or In the case of a film). In one embodiment, the second precursor web 221 is compared to the first precursor web 220 such that the flap 207 of the IPS opening 204 extends slightly out of plane, if any, compared to the tuft 209. Sufficiently low elongation at break. The second precursor web 221 is at least about 10% smaller than the first precursor web 220, or at least about 30% smaller than that of the first precursor web 220, or at least about 50% smaller, or It may have an elongation at break as small as at least about 100%.

The number, spacing and size of the tufts 209 can be varied by changing the number, spacing and size of the teeth 510 and applying the corresponding dimension changes to the roll 104 and / or roll 102 as needed. have.

The tufted web 1 comprises a nonwoven first precursor web 220 having a basis weight of about 60 gsm to about 100 gsm (about 80 gsm is practical), a density of about 0.91 to about 0.94 g / cm 3 and about 20 gsm Polyolefin film (eg, polyethylene or polypropylene) having a basis weight of 2 may be formed from the second precursor web 221.

An enlarged view of teeth 510 is shown in FIG. 26. Teeth 510 may generally have a circumferential length dimension (TL) of about 1.25 mm measured from leading edge LE to trailing edge TE at tooth tip 111 and has a distance TD of about 1.5 mm. Can be evenly spaced from one another in the circumferential direction. To make the web 1 from the precursor web 24 having a total basis weight in the range of about 60 to about 100 gsm, the teeth 510 of the roll 104 have a length (TL) in the range of about 0.5 mm to about 3 mm. And a spacing TD of about 0.5 mm to about 3 mm, tooth height TH in a range of about 0.5 mm to about 5 mm, and a pitch of about 1 mm (about 0.040 inch) to about 5 mm (about 0.200 inch) P). Engagement depth E may be from about 0.5 mm to about 5 mm (up to a maximum equal to tooth height TH). Of course, E, P, TH, TD and TL can be varied independently of one another to achieve the desired size, spacing and area density of tuft 209.

The tooth tip 111 may be long and may have a generally longitudinal orientation corresponding to the long axis LA of the tuft 209 and the discontinuity 216. To obtain the tufted looped tufts 209 of the web 1, which may be described as terry cloth-like, LE and TE are very suitable for the cylindrical surface 1114 of the roll 104. It is believed to be nearly orthogonal. In addition, the transition from tip 111 to LE or TE should be a sharp angle, such as a right angle, with a radius of curvature small enough to allow teeth 510 to penetrate the second precursor web 221 at LE and TE. Without being bound by theory, having a tip transition at a relatively steep angle between the tip of the tooth 510 and LE and TE allows the tooth 510 to form the first precursor web 220 and the second precursor web 221. It is believed that the "clean", ie, local reliably penetrates, such that the first face 12 of the resulting web 1 has a tuft 209. When so treated, the web 1 may not be imparted with any particular elasticity beyond what the first precursor web 220 and the second precursor web 221 may originally have. Drilling through the second precursor web 221 may result in a small portion of the second precursor web 221 forming a "confetti" or small piece.

Web 1 with tufts 209 may be used as part of topsheet 20 or topsheet 20 of absorbent article 10. The web 1 with tufts 209, when used, absorbs the absorbent article due to the combination of good fluid capture and distribution to the absorbent core 40 and good anti-wetting against the body facing surface of the topsheet 20. It can be beneficial as a topsheet 20 for. Rewetting can be a result of at least two causes: (1) squeezing out of absorbed fluid due to pressure on the absorbent article 10; And / or (2) moisture trapped in or on topsheet 20.

Surface textures at various portions of the topsheet 20 may be generated by providing tufts 209. Tuft 209 may be oriented such that tuft 209 includes a portion of the body facing surface 22 of topsheet 20. Tuft 209 may be oriented such that tuft 209 is oriented on the garment facing surface of topsheet 20.

US Patent Application Publication No. 20040131820 A1, filed December 16, 2003, in the name of Turner et al., US Patent Application Publication No. 20040265534 A1, filed December 16, 2003, in the name of Kuro et al. US Patent Application Publication No. 20040265533 A1 filed December 16, 2003, in the name of Hoing et al., US Patent Application Publication No. 20040229008 A1, Kuro, filed December 16, 2003 in the name of Hoing et al. U.S. Patent Application Publication No. 20050281976 A1, filed June 17, 2005, in the name of, U.S. Patent Application Publication No. 20050281976 A1, filed June 17, 2005, in the name of Kuro, et al. Various structures and methods of making such tufts 209 are disclosed.

Topsheet 20 may be fabricated using nonwoven first precursor web 220 and fluid impermeable or fluid permeable polyethylene film second precursor web 221. However, the basis weight of the component web may generally vary due to cost and gain considerations, and a total basis weight of about 20 gsm to about 80 gsm may be desirable for the web 1. When made as a film / nonwoven laminate, the web 1 can combine the softness of the fiber tufts and the fluid capillary phenomenon with the rewet prevention of the fluid impermeable polymer film.

Embossing portion 140 may be formed in a substrate including topsheet 20 by passing the substrate between a smooth roller and an embossing roller having a protrusion thereon, as shown in FIG. 6. As the substrate passes between the smooth roller and the embossing roller, the thermoplastic fibers in the substrate deform and bond together with each other, and the fiber density of the nonwoven in the embossing portion 140 is greater than for the portion adjacent to the embossing portion 140. Big.

In one embodiment, the absorbent core 40 may be a portion of either the first precursor web 220 or the second precursor web 221 or any one of the first precursor web 220 or the second precursor web 221. It may be between a laminate web comprising a first precursor web 220 and a second precursor web 221 such that it is not between the absorbent core 40 and the backsheet 30.

The texture can be measured using a GFM Mikrocad Optical Profiler instrument, available from GFMesstechnik GmbH, D14513 Teltow / Berlin Bartesstrasse 21, Germany. . The GE Microcad Optical Profiler instrument includes a compact optical measurement sensor based on digital micro mirror projection, which consists of the following main components: a) with a 1024 × 768 direct digitally controlled micromirror; One DMD projector, b) a CCD camera with high resolution (1300 x 1000 pixels), c) a projection optics adapted to a measurement area of at least 40 mm x 40 mm to 4 mm x 3 mm, and d) matching resolution Recording optics; Table tripods based on small hard stone plates; Cold light source; Measurement, control, and evaluation computers; Measurement, control and evaluation software ODSCAD 4.0, English version; And adjusting probe for lateral (x-y) and vertical (z) correction.

The GEM microcad optical profiler system measures the surface height of the sample using digital micro-mirror pattern projection technology. The result of the analysis is a map of surface height (z) versus xy displacement. The system has a 27 × 22 mm field of view with a resolution of 21 micrometers. The height resolution should be set at 0.10 to 1.00 micrometers. The height range is 64,000 times the resolution.

To measure the texture of the material or composite material, the following can be performed: (1) Turn on the cold light source. The setting for the cold light source should be 4 and C, which should give 3000 K readings on the display; (2) turn on computers, monitors, and printers, and open ODSCAD 4.0 or higher microcad software; (3) Select the "Measurement" icon from the microcad task bar, then click the "Live Pic" button; (4) Place a 5 mm × 5 mm sample of a fibrous structured product adjusted to a temperature of about 23 ° C. ± 1 ° C. (73 ° F. ± 2 ° F.) and a relative humidity of 50% ± 2% below the projection head and provide optimal focus. Adjust the distance for; (5) Click the "Pattern" button repeatedly to project one of several focusing patterns to assist in achieving optimal focus (software cross hair is a cross that is projected when optimal focus is achieved). Must be aligned with the hair). Position the projection head perpendicular to the sample surface; (6) Adjust image brightness by changing the aperture on the camera lens and / or changing the camera "gain" setting on the screen. To limit the amount of electronic noise, gain is set to the lowest practical level while maintaining optimal brightness. When the illumination is optimal, the red circle at the bottom of the screen labeled "I.O." will turn green; (7) select a standard measurement type; (8) Click on the "Measure" button. This will freeze the live image on the screen and at the same time the surface capture process will begin. It is important to keep the sample still during this time to avoid blurring of the captured image. A fully digitized surface data set will be captured in approximately 20 seconds; (9) If the surface data is satisfactory, save the data as a computer file with a ".omc" extension. It will also save the camera image file ".kam"; (10) Click on the clipboard / man icon to move the surface data to the analysis portion of the software; (11) Now click on the "Draw Lines" icon. A line is drawn through the center of the area of the feature defining the texture of interest. Click the Show Sectional Line icon. In the section plot, click on any two points of interest, for example, peaks and baseline, then click the vertical distance tool to measure height in micrometers, or click adjacent peaks, Use the horizontal distance tool to determine; (12) For height measurements, at least five measurements per line, use three lines, discard the highest and lowest values for each line, and determine the average of the remaining nine values. In addition, record the standard deviation, maximum ¹˜, and minimum values. For the x and / or y direction measurements, the average of the seven measurements is determined. In addition, the standard deviation, maximum and minimum values are recorded. Criteria that can be used to characterize and distinguish textures include, but are not limited to, masked areas (ie, areas of features), open areas (areas without features), spacing, in-plane size, and height. If the difference between the two means of texture characterization is less than 20% likely to happen by chance, the textures can be considered different from each other.

The textures can also be visually compared and distinguished from one another by a common observer with 20/20 vision from a distance of 30 cm, at least equivalent to the illuminance of a standard 100 watt incandescent white light bulb. If the average observer can distinguish between textures, the textures can be considered different from each other.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, each such dimension, unless otherwise specified, is intended to mean both the recited value and the functionally equivalent range around that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

All documents cited in the detailed description for carrying out the invention are incorporated herein by reference in their relevant part and no citation of any document should be construed as an admission to the prior art for the present invention. In the event that any meaning or definition of a term in this specification conflicts with any meaning or definition of the same term in the literature incorporated by reference, the meaning or definition given to the term in this specification shall prevail.

While specific embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Accordingly, all such changes and modifications that fall within the scope of the invention are intended to be included in the appended claims.

Claims (11)

An absorbent article (10) comprising a topsheet (20) and an absorbent core (40) facing in contact with the topsheet (20),
The topsheet 20 has a longitudinal centerline L and a transverse centerline T, the topsheet 20 having a central region 50, an inner middle region 60, an outer middle region 70 and An edge region 80, wherein the inner middle region 60 is between the central region 50 and the outer middle region 70, and the outer middle region 70 is the inner middle region 60. And between the edge region (80);
The central region 50 has a central region body facing surface 52 having a central region texture 54, and the inner middle region 60 has an inner middle region body having an inner middle region texture 64. Having an outer surface 62, the outer middle region 70 having an outer middle region body facing surface 72 having an outer middle region texture 74, and the edge region 80 having an edge region texture 84. Has an edge region body opposing surface 82 having a;
The center region texture (54) is different from the inner middle region texture (64), the outer middle region texture (74) and the edge region texture (84);
The inner middle region texture (64) is different from the outer middle region texture (74) and the edge region texture (84);
The outer middle region texture (74) is different from the edge region texture (84);
The central region 50 is on the longitudinal center line L;
At least one of the central region 50, the inner middle region 60, the outer middle region 70, and the edge region 80 includes tufted fibers 206,
The central region 50 and the inner middle region 60 include a film 100 that faces the nonwoven 130, and the film 100 in the central region 50 includes an opening 110. And the tufted fibers 206 from the nonwoven 130 in the inner middle region 60 protrude through the film 100.
Absorbent article. delete delete An absorbent article (10) comprising a topsheet (20) and an absorbent core (40) facing in contact with the topsheet (20),
The topsheet 20 has a longitudinal centerline L and a transverse centerline T, the topsheet 20 having a central region 50, an inner middle region 60, an outer middle region 70 and An edge region 80, wherein the inner middle region 60 is between the central region 50 and the outer middle region 70, and the outer middle region 70 is the inner middle region 60. And between the edge region (80);
The central region 50 has a central region body facing surface 52 having a central region texture 54, and the inner middle region 60 has an inner middle region body having an inner middle region texture 64. Having an outer surface 62, the outer middle region 70 having an outer middle region body facing surface 72 having an outer middle region texture 74, and the edge region 80 having an edge region texture 84. Has an edge region body opposing surface 82 having a;
The center region texture (54) is different from the inner middle region texture (64), the outer middle region texture (74) and the edge region texture (84);
The inner middle region texture (64) is different from the outer middle region texture (74) and the edge region texture (84);
The outer middle region texture (74) is different from the edge region texture (84);
The central region 50 is on the longitudinal center line L;
At least one of the central region 50, the inner middle region 60, the outer middle region 70, and the edge region 80 includes tufted fibers 206,
The central region 50 and the inner middle region 60 include a first nonwoven fabric 131 and a second nonwoven fabric 132 in a face-to-face relationship, the first nonwoven fabric in the central region 50 ( 131 includes an opening 110,
Tufted fibers 206 from the second nonwoven 132 protrude through the first nonwoven 131 in the inner middle region 60.
Absorbent article. delete The method according to claim 1 or 4,
Selected from the group consisting of incontinence products, sanitary napkins and diapers
Absorbent article. The method according to claim 1 or 4,
The outer middle region 70 and the edge region 80 include tufts 209, the outer middle region 70 has an outer middle region tuft area density, and the edge region 80 has an edge Has an area tuft area density, the outer middle area tuft area density is different from the edge area tuft area density.
Absorbent article. The method according to claim 1 or 4,
The outer middle region 70 and the edge region 80 include tufts 209, the outer middle region 70 has an outer middle region tuft height, and the edge region 80 has an edge region. Has a tuft height, the outer mid-region tuft height is different from the edge region tuft height
Absorbent article. The method according to claim 1 or 4,
The central region 50, the inner middle region 60, the outer middle region 70 and the edge region 80 are disposed on a line parallel to the longitudinal center line L. FIG.
Absorbent article. The method according to claim 1 or 4,
The inner middle region 60, the outer middle region 70 and the edge region 80 are disposed on a line orthogonal to the longitudinal center line L. FIG.
Absorbent article. The method according to claim 1 or 4,
The absorbent article 10 has a length and a width, each of the central region 50, the inner middle region 60, the outer middle region 70 and the edge region 80 being 5% of the length of the absorbent article and the absorbent article. An area exceeding a product of 5% of the width of the article, the width being measured at the center of each region
Absorbent article.

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